2003 Expedition Face Lift Begins

[Vancouver Bob]

It always seemed like whenever I changed oil, I always wound up with more on the floor than I had in the catch pan. I have always said if I build another house I'm going to put a pit in the garage. But then I thought about it and I'd rather just pay somebody to do it rather than mess with it.

I do enjoy working on the vehicle though... it gives me a sense of accomplishment. Sometimes it's just faster or less of a hassle and I have a little more confidence in what I'm doing vs some kick

It always seemed like whenever I changed oil, I always wound up with more on the floor than I had in the catch pan. I have always said if I build another house I'm going to put a pit in the garage. But then I thought about it and I'd rather just pay somebody to do it rather than mess with it.

Well that's because you're older and wiser than me

I remember a couple of years back, I was getting ready to drive down to LA to take my girls to Disneyland. Day prior to departure I was going to change the oil real quick. All went well. When putting on the filter it felt strange as I was tightening it on... like it didn't tighten up like usual, felt a little squishier. Got it tightened up, started the engine, and after just a few seconds I'm hearing this slapping noise from the engine so I shut it down real quick. Looked under the hood that was still open and saw oil EVERYWHERE! The filter gasket got dislodged and was what was preventing the filter from seating and tightening properly. Oil was squirting into the fan which in turn sprayed oil all over. Now that was a mess!

 

[ExpeditionAndy]

Well that's because you're older and wiser than me

But not by much! LOL

I do enjoy working on the vehicle though... it gives me a sense of accomplishment. Sometimes it's just faster or less of a hassle and I have a little more confidence in what I'm doing vs some kick

I remember a couple of years back, I was getting ready to drive down to LA to take my girls to Disneyland. Day prior to departure I was going to change the oil real quick. All went well. When putting on the filter it felt strange as I was tightening it on... like it didn't tighten up like usual, felt a little squishier. Got it tightened up, started the engine, and after just a few seconds I'm hearing this slapping noise from the engine so I shut it down real quick. Looked under the hood that was still open and saw oil EVERYWHERE! The filter gasket got dislodged and was what was preventing the filter from seating and tightening properly. Oil was squirting into the fan which in turn sprayed oil all over. Now that was a mess!

Back when I was in my late teens or early 20s I was changing oil at my mom and dad's house. Dad had one of these catch cans that had a pan with a drain in the center that allowed the oil to drain into the interior of the pan. The first mistake I made was forgetting to pull the center drain plug. I realized my mistake when the oil started to overflow the pan and I had to reach into the hot oil to pull the plug which took a couple of tries because I didn't remember exactly where it was. The second mistake was failing to check the cap for the internal storage compartment. I crawled out from underneath grabbed a rag to clean my hands and then when it the house to wait for it to drain when I came out about 30-minutes later, oil was running out from under the car and I couldn't figure out what was going on until I looked under the car and saw oil dripping out from the cap. The mess was incredible, dad wasn't too happy, and I never made that mistake again.

 

[Vancouver Bob]

But not by much! LOL


Back when I was in my late teens or early 20s I was changing oil at my mom and dad's house. Dad had one of these catch cans that had a pan with a drain in the center that allowed the oil to drain into the interior of the pan. The first mistake I made was forgetting to pull the center drain plug. I realized my mistake when the oil started to overflow the pan and I had to reach into the hot oil to pull the plug which took a couple of tries because I didn't remember exactly where it was. The second mistake was failing to check the cap for the internal storage compartment. I crawled out from underneath grabbed a rag to clean my hands and then when it the house to wait for it to drain when I came out about 30-minutes later, oil was running out from under the car and I couldn't figure out what was going on until I looked under the car and saw oil dripping out from the cap. The mess was incredible, dad wasn't too happy, and I never made that mistake again.

Great story!! And some things we just never learn... like I keep thinking I need to put the nitrile gloves on AFTER I get my hands dirty.

 

[Rockclutch]

Great story!! And some things we just never learn... like I keep thinking I need to put the nitrile gloves on AFTER I get my hands dirty.

LOL, that's me too
And " what are these leftover bolts for?

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[Vancouver Bob]

Hi Scoot...

Here are some pictures of how I got the bumper mounted up... I used some shims to set the spacing between fender and bumper. The one shown in the picture was out of position.




Here's a pic of how I had the top of the frame reinforced with a little plate...




Driver side... not completely bolted up. Sitting a little closer to the frame than I would like...



Picture from the front... left and right gaps don't quit match but it was good enough to not be a high enough priority to fix it just yet



driver side after adding to the bumper to get it to fit up to the fender better... tighter fit than I would like.

 

[ExpeditionAndy]

@Vancouver Bob, just out of curiosity, do you still have the front air bag sensors and if so, do they mount to the bumper?

 

[John Christopher]

I do enjoy working on the vehicle though... it gives me a sense of accomplishment. Sometimes it's just faster or less of a hassle and I have a little more confidence in what I'm doing vs some kick



Well that's because you're older and wiser than me

I remember a couple of years back, I was getting ready to drive down to LA to take my girls to Disneyland. Day prior to departure I was going to change the oil real quick. All went well. When putting on the filter it felt strange as I was tightening it on... like it didn't tighten up like usual, felt a little squishier. Got it tightened up, started the engine, and after just a few seconds I'm hearing this slapping noise from the engine so I shut it down real quick. Looked under the hood that was still open and saw oil EVERYWHERE! The filter gasket got dislodged and was what was preventing the filter from seating and tightening properly. Oil was squirting into the fan which in turn sprayed oil all over. Now that was a mess!

I used to change my oil myself many years ago but not anymore. When you consider the price of the oil and filter, having to get under the truck and do the change, then taking the oil to be recycled, it's a PIA. Also stores are always running specials and it cost $25 to 30 for a change. It's just not worth it to me even if I don't spill any oil. The only oil I change is in my boat and that's once a year before winterizing. Take care.

 

[Vancouver Bob]

I used to change my oil myself many years ago but not anymore. When you consider the price of the oil and filter, having to get under the truck and do the change, then taking the oil to be recycled, it's a PIA. Also stores are always running specials and it cost $25 to 30 for a change. It's just not worth it to me even if I don't spill any oil. The only oil I change is in my boat and that's once a year before winterizing. Take care.

That is so true, John... I’m about at that point too. Over here we can put oil, anti-freeze, tranny fluid out with the recycle so a little less hassle. But from a cost and time perspective probably better to just take it to one of the oil change places.

 

[Vancouver Bob]

@Vancouver Bob, just out of curiosity, do you still have the front air bag sensors and if so, do they mount to the bumper?

Actually, when taking things apart the only thing attached to the bumper/shroud were the fog lights. But now you have me curious about actual location... the accelerometers could be pretty much anywhere I would think. I'll have to Google that one .

 

[FRD88]

Actually, when taking things apart the only thing attached to the bumper/shroud were the fog lights. But now you have me curious about actual location... the accelerometers could be pretty much anywhere I would think. I'll have to Google that one .

Please let us know what you come up with. I will be replacing my front bumper with something very similar to your and this is one of the questions I have as well. Really enjoy this post by the way! Thanks for all the great info Vancouver Bob, I may be reaching out to you if I come across any more questions.

 

[Vancouver Bob]

Well, I'm going to live up to my words and have an appointment to have new gears and lockers installed. I didn't win the lottery but am getting a year end bonus so a good chunk of it is going to the Expedition. Going with the 4.56 gears and ARB lockers with onboard air. Was going to go with just the rear locker but I don't want to cheap out now and wish I did the front while I had the opportunity. I'm sure I'll find a way to justify it to myself eventually .

 

[Rockclutch]

Well, I'm going to live up to my words and have an appointment to have new gears and lockers installed. I didn't win the lottery but am getting a year end bonus so a good chunk of it is going to the Expedition. Going with the 4.56 gears and ARB lockers with onboard air. Was going to go with just the rear locker but I don't want to cheap out now and wish I did the front while I had the opportunity. I'm sure I'll find a way to justify it to myself eventually .

Cool beans Bob!
What reason(s) made you choose 4.56 gears in particular? Read quite a few posts about 4.11s as well so wondering what advantage you are seeing? Going to be making a choice for my rig in '18 as I'm currently on 3.73.
I think you are going from 3.73 right?
Appreciate any guidance on this.
I'm curious and love to modify my stuff (a curse perhaps) and geek out in general. I've no intention of selling my expy and have overlander dreams regularly.[emoji41]
So I must mod.

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[Vancouver Bob]

Cool beans Bob!
What reason(s) made you choose 4.56 gears in particular? Read quite a few posts about 4.11s as well so wondering what advantage you are seeing? Going to be making a choice for my rig in '18 as I'm currently on 3.73.
I think you are going from 3.73 right?
Appreciate any guidance on this.
I'm curious and love to modify my stuff (a curse perhaps) and geek out in general. I've no intention of selling my expy and have overlander dreams regularly.[emoji41]
So I must mod.

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Hi Rock... yes, we have the same gears. Funny you mention the 4.11's because that's where my mind was a few months ago. Seemed like that was the right gear choice to get me back to stock ratio. But the more I looked, seemed like many were saying go 4.56 because you'll wish you had. There's a 2007 Expedition that went from 3.73's to 4.56's and they said it was awesome... of course they don't have the 4.11's to compare. When I called a couple of shops and talked about what I wanted to do, they both were like, "Yea, 4.56's are the way to go". My reasoning is heavier tires, heavier bumper, maybe rear bumper at some point... so a little higher gearing may not be a bad thing. The other side is going from 3.73's to 4.11's not that big of a jump. Probably a horrible reason to base a decision on though .

I've been dreaming of the ovelanding thing too... sounds like it would be a lot of fun and a good way to see parts of the area that not many get to see.

 

[Rockclutch]

Hi Rock... yes, we have the same gears. Funny you mention the 4.11's because that's where my mind was a few months ago. Seemed like that was the right gear choice to get me back to stock ratio. But the more I looked, seemed like many were saying go 4.56 because you'll wish you had. There's a 2007 Expedition that went from 3.73's to 4.56's and they said it was awesome... of course they don't have the 4.11's to compare. When I called a couple of shops and talked about what I wanted to do, they both were like, "Yea, 4.56's are the way to go". My reasoning is heavier tires, heavier bumper, maybe rear bumper at some point... so a little higher gearing may not be a bad thing. The other side is going from 3.73's to 4.11's not that big of a jump. Probably a horrible reason to base a decision on though .

I've been dreaming of the ovelanding thing too... sounds like it would be a lot of fun and a good way to see parts of the area that not many get to see.

Hi Bob,
Thanks for the feedback. I'd been kinda stuck on 4.11s as a given. Can't wait to hear your experience on the 4.56 results. Totally rethinking my options now and starting to hunt down more information.

Now....where'd I put that piggy bank?

Merry Christmas
Phil

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[Vancouver Bob]

Hi Bob,
Thanks for the feedback. I'd been kinda stuck on 4.11s as a given. Can't wait to hear your experience on the 4.56 results. Totally rethinking my options now and starting to hunt down more information.

Now....where'd I put that piggy bank?

Merry Christmas
Phil

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Hi Phil.

Here is the Expy that regeared to the 4.56's... always nice to hear the experience from others doing similar things...



They're also on this forum... Adventure Driven.

Merry Christmas to you too!

Bob

 

[ExpeditionAndy]

Bob,

What will your RPMs be at 70 MPH with 4.56 gears? Gear ratios always confuse me. Is it the higher the number the lower the gear ratio?

 

[Vancouver Bob]

Bob,

What will your RPMs be at 70 MPH with 4.56 gears? Gear ratios always confuse me. Is it the higher the number the lower the gear ratio?

I don't have any actual data but if I calculate things... I should have been turning about 1943 RPM with the 3.73 gears and stock (31.6") tires. With the 35" tires I should be at 1755 RPM's or so. Going with 4.11 gears would take me back up to 1933 RPM's and the 4.56's would take me to 2145 RPM's. Thinking the extra RPM's could be useful to offset increased drag of a roof tent. Giving myself room to grow .

 

[ExpeditionAndy]

I don't have any actual data but if I calculate things... I should have been turning about 1943 RPM with the 3.73 gears and stock (31.6") tires. With the 35" tires I should be at 1755 RPM's or so. Going with 4.11 gears would take me back up to 1933 RPM's and the 4.56's would take me to 2145 RPM's. Thinking the extra RPM's could be useful to offset increased drag of a roof tent. Giving myself room to grow .

Okay, that's still hard for me to understand. I was thinking that being under 2000 was better for gas mileage, but if you put larger diameter tires on don't the RPMs go down. I'm not sure how that works with the power curve.

 

[Vancouver Bob]

Hi Andy... you're right... bigger tires, lower RPM's for the same speed. Engine and tranny have to work harder to keep things moving. It's easier for me to compare to a bike... when you're in too small of a gear for the speed, you have to really stand on it to keep things moving vs shifting to a taller gear, getting RPM's up, and taking less overall effort. with the 35" tires my gas mileage dropped to about 11 from 14. Hoping to get some of that back with the new gears.

It's Christmas Eve!! What are we doing on the computer!?

Merry Christmas!

 

[Vancouver Bob]

Well... I bit the bullet over the holiday break and got the new gears installed. Went with the 4.56's. As a last minute sanity check I talked to the guys at the shop about 4.11's vs 4.56's and they said the 4.11's aren't that big of a step up from the 3.73's and that I wouldn't even feel the difference. So stuck with the 4.56's.

I must say I'm happy with the results! Where she used to labor to keep speed on a gradual incline she now maintains speed with little effort. On steeper grades, where I would need to keep pushing the accelerator while still losing speed until she down shifted, I now get a good response, sometimes even while staying in OD. Overall she just feels lighter and more responsive.

I do need to get my computer updated because while with the 35" tires I ran about 10% faster than speedo, I'm now running about 10% slower than the speedo. I must say that the difference, while noticeable and positive, it wasn't extreme... so I can see why they said the 4.11's wouldn't be noticeable, certainly much more subtle. Speedo would have been correct though .



Rear end ready to be re-installed... old ring & pinion and diff in the back.



Front end close to being done. I decided to go ahead and have front and rear lockers installed. Almost decided to pass on the fronts and put the money towards a winch but my testosterone kept me from making such a practical decision.



When they asked where I wanted the switches... I thought the left side of the dash, right above the hood release would be the easiest.... OR... tucked away where the ash tray was. I think they couldn't pass on the opportunity to put them somewhere inconspicuous for that James Bond look... glad they were willing to go to the trouble to mount them there!